Audi Q7 2007 Repair Manual
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Audi Q7 2007 Repair Manual

Fuel injection and ignition
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Service
Repair Manual
Audi Q7 2007 ➤
Fuel Injection and Ignition
Engine ID
Edition 02.2015
Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not
permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability
with respect to the correctness of information in this document. Copyright by AUDI AG.
Service Department. Technical Information
CJTB CJTC CNA
A
CJW
CJW
CJW
B
C
E
CTW
CTW
A
B

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  • Page 1 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 2 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 3: Table Of Contents

    Intake Flap Control Vacuum Actuator, Removing and Installing ....permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Injection System .
  • Page 4 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 5: Multiport Fuel Injection

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ The vehicles have a crash fuel shut-off. It reduces the risk of permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability fire in an accident because the fuel pump relay switches the with respect to the correctness of information in this document.

  • Page 6: Safety Precautions, Test And Measuring Instruments During Test Drive

    Fuel System Safety Precautions Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability WARNING with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 7 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not be disconnected before opening the fuel system. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 8: Injection System Safety Precautions

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not injection and ignition system, always observe the following: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 9: Pressure, Reducing In High Pressure Area

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Note the following when working on the fuel system: with respect to the correctness of information in this document.

  • Page 10: Fuel System, Checking For Leaks

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 11: Vacuum System

    Red = vacuum diaphragm supply line. ♦ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG. Blue = control line to the intake manifold runner control vac‐...
  • Page 12 Valve - N489- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 10 - Vacuum Actuator with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 13: Vacuum System, Checking

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not head permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 14 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 15 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability gine compartment.
  • Page 16 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Remove the bolt -2- and bracket -3-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 17 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Check the coolant level. Refer to ⇒ Fuel Injection and Ignition; permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Rep. Gr. 19 ; Cooling System, Coolant, Draining and Filling .

  • Page 18: Injection System

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ⇒ “3.16 High Pressure Pump, Removing and Installing”, permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability page 49 with respect to the correctness of information in this document.
  • Page 19 ⇒ “4.2 Engine Control Module J623 , Removing and Installing”, page 58 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 20 ⇒ “2.5 Camshaft Position Sensor G40 / Camshaft Position Sensor 2 G163 , Removing and Installing”, Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability page 71 with respect to the correctness of information in this document.
  • Page 21 Location”“ , page 23 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ Removing and installing. Refer to with respect to the correctness of information in this document.
  • Page 22 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 23 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 24 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 25 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 26 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 27 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Connector for the Charge Air Pressure Sensor - G31- / In‐...
  • Page 28 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Gr. 19 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 29: Overview - Air Filter

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Gr. 26 . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 30 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 31: Engine Covers, Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 32: Air Filter Housing, Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 33 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 34: Overview - Intake Manifold Lower Section, Fuel Rail And Fuel Injectors

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 35 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ❑ Coat the ball with clean permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability engine oil; do not oil the with respect to the correctness of information in this document.
  • Page 36 ❑ To install, press in by hand Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability 26 - Release Lever with respect to the correctness of information in this document.
  • Page 37 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Tighten the bolts in three steps as follows: permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 38: Intake Air Temperature Sensor - G42- / Manifold Absolute Pressure Sensor - G71- , Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 39 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 40: Control Valve Control Unit J808 , Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 41 – Disconnect the connector -2- from the intake manifold runner Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability position sensor and remove the vacuum hose -3-.
  • Page 42 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 43: Fuel Injectors, Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 44 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not jector. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 45 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability sembly Cone - T10133/5- with new combustion chamber seal with respect to the correctness of information in this document.

  • Page 46: Fuel Pressure And Residual Pressure Before High Pressure Pump, Checking

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not head using the Injector/Combustion Chamber Seal Tool Set - permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Assembly Mandrel - T10133/9- ; when doing this, note the with respect to the correctness of information in this document.
  • Page 47 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 48 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 49: Overview - High Pressure Pump

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not moved permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 50 10 - Seal Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ❑ Replacing with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 51: High Pressure Line, Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ⇒ “1.6 Pressure, Reducing in High Pressure Area”, page 5 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 52 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 53: High Pressure Pump, Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ Torque Wrench 1331 Insert - Open Ring Wrench - 14mm - with respect to the correctness of information in this document.
  • Page 54 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 55 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not essary. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 56: Overview - Heated Oxygen Sensors

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 57: Heated Oxygen Sensors G39 / G108 / G130 / G131 , Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 58 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 2 - 3337/2- . permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 59 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not the sensor body. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 60: Engine Control Module

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not Special tools and workshop equipment required permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 61 ♦ Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability mains fully functional (for example measurement of signals with respect to the correctness of information in this document.

  • Page 62: Engine Control Module J623 , Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not ♦ Small commercially available locking pliers permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 63 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 64 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 65: Special Tools

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 66 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ Torque Wrench 1331 Insert - Open Jaw - 17mm - VAG1331/6- with respect to the correctness of information in this document.
  • Page 67 ♦ Hose Clip Pliers - VAS6362- Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability ♦ Pry Lever - 80-200- with respect to the correctness of information in this document.
  • Page 68 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 69: Ignition/Glow Plug System

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability Fault Finding, repairs or checking the components, it may be with respect to the correctness of information in this document.
  • Page 70 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 71: Ignition, Servicing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not sor 2 G163 , Removing and Installing”, page 71 permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 72 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not 6 - Spark Plug permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 73: Ignition Coils With Power Output Stages, Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Remove the vacuum hose -1- from the air guide hose con‐ permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability nection.

  • Page 74: Knock Sensor 1 G61 / Knock Sensor 2 G66 , Removing And Installing

    Install in reverse order of removal. Note the following: Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability •...

  • Page 75: Camshaft Position Sensor G40 / Camshaft Position Sensor 2 G163 , Removing And Installing

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability – On a vehicle with air suspension, activate vehicle lift mode.
  • Page 76 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not – Remove the cover -2-. permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.

  • Page 77: Special Tools

    Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 78 Protected by copyright. Copying for private or commercial purposes, in part or in whole, is not permitted unless authorised by AUDI AG. AUDI AG does not guarantee or accept any liability with respect to the correctness of information in this document. Copyright by AUDI AG.
  • Page 79 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 80 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.
  • Page 81 All rights reserved. Information contained in this document is based on the latest information available at the time of printing and is subject to the copyright and other intellectual property rights of Audi of America, Inc., its affiliated companies and its licensors. All rights are reserved to make changes at any time without notice. No part of this document may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, nor may these materials be modified or reposted to other sites, without the prior expressed written permission of the publisher.

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